Auxiliary heating assembly for use with residential air handlers

ABSTRACT

An auxiliary heating assembly for use with a residential air handler including a fan assembly, the auxiliary heating assembly includes a heating apparatus arranged in a geometric shape, wherein the heating apparatus includes an opening, the opening substantially position in a center of the geometric shape.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is related to, and claims the priority benefit of, U.S. Provisional Patent Application Ser. No. 62/000,699 filed May 20, 2014, the contents of which are hereby incorporated in their entirety into the present disclosure.

TECHNICAL FIELD OF THE DISCLOSED EMBODIMENTS

The presently disclosed embodiments generally relate to heating, ventilation, and air-conditioning (HVAC) systems, and more particularly, to an auxiliary heating assembly for use with residential air handlers.

BACKGROUND OF THE DISCLOSED EMBODIMENTS

Residential air handlers may include auxiliary heating packages to provide supplemental heat when the residential air handler alone cannot satisfy the heating demand. In some instances the auxiliary heating packages are integrated within the residential air handler, and in other instances, the auxiliary heating package is enclosed in a separate compartment, typically on top of the residential air handler. Generally, the auxiliary heating package contains electrical heating coils arranged in linear rows. When used with a residential air handler having an axial fan, this linear arrangement could adversely affect the operation of the residential air handler as minimal air would pass through the center section of rows; thus causing temperature limits to be activated. There is therefore a need for an auxiliary heating package that will not adversely affect the operation of a residential air handler having an axial fan.

SUMMARY OF THE DISCLOSED EMBODIMENTS

In at least one embodiment, an auxiliary heating assembly is provided. The auxiliary heating assembly includes a heating apparatus arranged in a geometric shape to include an opening, wherein the opening is substantially positioned in a center of the geometrical shape. In one embodiment, the geometric shape is selected from a group consisting of: circular, toroid, triangular, square, pentagonal, pyramid, and hexagonal. In one embodiment, an opening length of the opening comprises between approximately 10% and approximately 50% of an apparatus length of the heating apparatus. In one embodiment, the heating apparatus includes at least one electrical coil. In another embodiment, the heating apparatus includes at least one conduit configured to circulate a medium therethrough.

In at least one embodiment, a residential air handler is provided. In one embodiment, air handler includes an air handler enclosure including an interior surface and an exterior surface. In one embodiment, the interior surface of the air handler enclosure includes a plurality of apertures disposed thereon. In one embodiment, a rail assembly is coupled to the interior surface of the air handler enclosure. In one embodiment, a portion of the rail assembly is removable from the air handler enclosure. The air handler further includes a coil assembly disposed within the air handler enclosure. The air handler further includes a fan assembly disposed within the enclosure and located in a position adjacent to the coil assembly. In one embodiment, the fan assembly is coupled to the rail assembly. In one embodiment, the fan assembly 28 includes an axial fan. In one embodiment, the axial fan further includes a stator assembly, including a plurality of vanes and a hub, coupled thereto. In one embodiment, the auxiliary heating assembly is disposed within the air handler enclosure and positioned adjacent to the fan assembly. In another embodiment, the auxiliary heating assembly is disposed within an auxiliary heating assembly enclosure, and positioned adjacent to the air handler enclosure.

In at least one embodiment, an HVAC system is provided. The HVAC system includes an air handler in fluid communication with an outdoor unit assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments and other features, advantages and disclosures contained herein, and the manner of attaining them, will become apparent and the present disclosure will be better understood by reference to the following description of various exemplary embodiments of the present disclosure taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a schematic diagram of an HVAC system.

FIGS. 2A-D are schematic diagrams of auxiliary heating assemblies;

FIGS. 3A-B are schematic diagrams of residential air handlers; and

FIG. 4 is a perspective view of an auxiliary heating assembly coupled to a fan assembly.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENTS

For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure is thereby intended.

FIG. 1 illustrates an HVAC system 10 including an air handler 12 in fluid communication with an outdoor unit assembly 14, for example, an air conditioner or a heat pump. The air handler 12 and outdoor unit assembly 14 are operable to provide conditioned air to a space 16 via a plurality of conduits 18.

FIGS. 2A-2D illustrates embodiments of the auxiliary heating assembly 32. The auxiliary heating assembly 32 includes a heating apparatus 36 arranged in a geometric shape to include an opening 38, wherein the opening 38 is substantially positioned in a center of the geometrical shape. As shown in FIG. 2A-2D, the geometric shape may be chosen from a group consisting of circular, triangular, square, and pentagonal. In one embodiment, an opening length 37 of the opening 38 comprises between approximately 10% and approximately 50% of an apparatus length 39 of the heating apparatus 36. It will also be appreciated that other geometrical shapes, such as hexagonal, pyramidal, and toroid to name a few non-limiting examples, may be used to arrange the heating apparatus 36. In one embodiment, the heating apparatus 36 includes at least one electrical coil. In another embodiment, the heating apparatus 36 includes at least one conduit configured to circulate a medium therethrough. For example, the heating apparatus 36 may be configured to circulate hot water therethrough to provide auxiliary heating.

FIGS. 3A and 3B illustrate embodiments of an air handler 12. In one embodiment, air handler 12 includes an air handler enclosure 20 including an interior surface 22 and an exterior surface 24. In one embodiment, the interior surface 22 of the air handler enclosure 20 includes a plurality of apertures (not shown) disposed thereon. In one embodiment, a rail assembly (not shown) is coupled to the interior surface 22 of the air handler enclosure 20. In one embodiment, a portion of the rail assembly is removable from the air handler enclosure 20. The air handler 12 further includes a coil assembly 26 disposed within the air handler enclosure 20. The coil assembly 26 is configured to circulate a medium, for example a refrigerant, therethrough. The air handler 12 further includes a fan assembly 28 disposed within the enclosure 20 and located in a position adjacent to the coil assembly 26. The fan assembly 28 is configured to produce an air flow stream 30 through the enclosure 12. In one embodiment, the fan assembly 28 is coupled to the rail assembly (not shown). In one embodiment, the fan assembly 28 includes an axial fan. In one embodiment, the axial fan further includes a stator assembly (not shown), including a plurality of vanes and a hub, coupled thereto. In one embodiment, as shown in FIG. 2A, an auxiliary heating assembly 32 is disposed within the air handler enclosure 20 and positioned adjacent to the fan assembly 28. It will be appreciated that the auxiliary heating assembly 32 may be positioned adjacent to the fan assembly 28 by mounting the auxiliary heating assembly 32 to the interior surface 22 of the air handler enclosure 20, mounting the auxiliary heating assembly 32 to the rail assembly, or mounting the auxiliary heating assembly 32 to the stator assembly to name a few non limiting examples. In another embodiment, as shown in FIG. 2B, an auxiliary heating assembly 32 is disposed within an auxiliary heating assembly enclosure 34, and positioned adjacent to the air handler enclosure 20. In the example shown in FIG. 4, to enable efficient heating from the auxiliary heating assembly 32, it will also be appreciated that the heating apparatus 36 is positioned substantially parallel to the air flow stream 30 from the fan assembly 28.

It will therefore be appreciated that the auxiliary heating assembly 32 includes a heating apparatus 36 arranged in a geometric shape to enable efficient heating by positioning the heating apparatus 36 substantially parallel to the air flow stream 30 from the fan assembly 28.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. 

What is claimed is:
 1. An auxiliary heating assembly for use with a residential air handler including a fan assembly, the auxiliary heating assembly comprising: a heating apparatus arranged in a geometric shape; wherein the heating apparatus includes an opening, the opening substantially position in a center of the geometric shape.
 2. The auxiliary heating assembly of claim 1, wherein the geometric shape is selected from a group consisting of: circular, toroid, triangular, square, pentagonal, pyramid, and hexagonal.
 3. The auxiliary heating assembly of claim 2, wherein an opening length of the opening comprises between approximately 10% and approximately 50% of an apparatus length of the heating apparatus.
 4. The auxiliary heating assembly of claim 1, wherein the heating apparatus comprises at least one electrical coil.
 5. The auxiliary heating assembly of claim 1, wherein the heating apparatus comprises at least one conduit.
 6. The auxiliary heating assembly of claim 1, wherein the heating apparatus is disposed within an enclosure.
 7. A residential air handler comprising: an enclosure including an interior surface and an exterior surface; a fan assembly disposed within the enclosure, the fan assembly configured to produce an air flow stream; and an auxiliary heating assembly positioned adjacent to the fan assembly and disposed within the enclosure; wherein the auxiliary heating assembly comprises: a heating apparatus arranged in a geometric shape; wherein the heating apparatus is substantially aligned with an air flow stream produced by the fan assembly.
 8. The residential air handler of claim 7, wherein the geometric shape is selected from a group consisting of: circular, toroid, triangular, square, pentagonal, pyramid and hexagonal.
 9. The residential air handler of claim 8, wherein an opening length of the opening comprises between approximately 10% and approximately 50% of an apparatus length of the heating apparatus.
 10. The residential air handler of claim 7, wherein the heating apparatus comprises at least one electrical coil.
 11. The residential air handler of claim 7, wherein the heating apparatus comprises at least one conduit.
 12. The residential air handler of claim 7, wherein the fan assembly comprises an axial fan.
 13. An HVAC system comprising: an air handler comprising an air handler enclosure, and a fan assembly disposed within the enclosure; and an auxiliary heating assembly comprising a heating apparatus arranged in a geometric shape, wherein the heating apparatus includes an opening, the opening substantially position in a center of the geometric shape.
 14. The HVAC system of claim 13, wherein the auxiliary heating assembly is disposed within the air handler.
 15. The HVAC system of claim 13, wherein the auxiliary heating assembly further comprises an auxiliary heating assembly enclosure.
 16. The HVAC system of claim 15, wherein the auxiliary heating assembly enclosure is positioned adjacent to the air handler enclosure.
 17. The HVAC system of claim 13, wherein the fan assembly comprises an axial fan.
 18. The HVAC system of claim 13, wherein the geometric shape is selected from a group consisting of: circular, toroid, triangular, square, pentagonal, and hexagonal.
 19. The HVAC system of claim of claim 18, wherein an opening length of the opening comprises between approximately 10% and approximately 50% of an apparatus length of the heating apparatus.
 20. The HVAC system of claim 13, wherein the heating apparatus comprises at least one electrical coil.
 21. The HVAC system of claim 13, wherein the heating apparatus comprises at least one conduit. 